Fabric-Faced Composites and Methods for Making Same

ABSTRACT

The present invention is directed to multiple layer composites suitable for use as wall and floor coverings, among other uses, that provide a strong durable structure and a soft textile or fabric face. The composite includes a face layer bonded to an adhesive layer such that the adhesive layer penetrates into the face layer. The face layer can have legs extending there from, and such legs are anchored by the adhesive layer to provide stronger attachment between the adhesive layer and the face layer. A backing layer may also be provided in contact with the adhesive layer such that the adhesive layer also embeds into the backing layer, and the legs extending from the face layer may penetrate into the backing layer.

CROSS-REFERENCE TO RELATED APPLICATIONS

The present application is a continuation of co-pending, commonly-ownedU.S. patent application Ser. No. 10/611,769, which was filed on Jul. 1,2003.

TECHNICAL AREA

The present invention relates to fabric-faced laminates for use as floorcoverings.

BACKGROUND

Floor coverings are generally selected based upon a combination offactors including aesthetic features such as the look and feel of thefloor covering and functional qualities such as retention of surfaceappearance, stain resistance, moisture resistance, ease of cleaning, andresistance to collection of dirt. For example, floor coveringinstallations in high traffic areas or areas prone to moisture andstains such as kitchens generally use solid surface cover materials forthe flooring or interior wall coverings such as wood, metal, marble,ceramic tile, vinyl or rubber. These products retain their surfaceappearance after heavy use and they are simple to keep clean. They alsoare resistant to stains and moisture, and less prone to harboringbacterial growth. However, these products lack the textile hand,softness or sound dampening qualities of textile products.

In installations where aesthetic qualities such as texture and softnessare desired, products such as tufted, knit, knotted or woven structures,including velour or velvet are used. These products provide softness andcushion, a soft textile hand and a degree of abrasion and wearresistance. Compared to rigid solid surfaced products, however, thesefloor coverings are less durable, tend to lose their texture with heavyuse, because the pile tends to mat or to be crushed with heavy traffic,tend to collect dust and dirt, provide spaces that allow the growth ofbacteria, and are difficult to clean and sanitize.

Attempts have been made to create products having both the desiredfunctional qualities of solid surface materials and the aestheticqualities of textile or fabric materials. For example, hybrid structureswith partially fibrous and partially solid faces are disclosed in U.S.Pat. No. 3,943,018. These hybrid structures, however, merely reduce butdo not eliminate the limitations of regular tufted, velour, or flockedtextile surfaces.

Other attempts provide flat or profiled, e.g., sculpted, surfacescontaining fibrous layers impregnated with a plastic matrix. Examples offibrous layers impregnated with a plastic matrix are disclosed in U.S.Pat. Nos. 4,035,215, 4,098,629, and 6,063,473. These floor coveringsgenerally have surfaces with a semi-fibrous feel, and the spaces betweenthe fibers may be sufficiently sealed to prevent bacterial penetrationand dirt collection. In addition, these floor coverings also provide ahigher matting resistance than regular upright-oriented fiberstructures. However, these floor covering products largely have a stiffleathery appearance rather than a soft textile feel, and the cost ofpreparing dimensionally-stable dense fibrous products, combined with thecost of impregnating and heat setting can be very high.

U.S. Pat. No. 3,860,469 discloses another technique to produceinexpensive, dirt and bacterial growth resistant, and abrasion resistantsurface covering materials with a textile fiber appearance in which flator textured film-like skins are placed on top of a pile-like surface.The resultant floor covering products combine the qualities of carpetwith the solidity of vinyl or rubber, but lack the textile quality andaesthetics of carpets.

Other attempts assemble a basically flat textile fabric over a sublayerof adhesive backed with various layers of sub-surface reinforcement. Forexample, International Patent Publication No. WO 99/19557 discloses awoven face fabric backed by reinforcing layers, and U.S. Pat. No.5,965,232 discloses a decorative fabric attached todimensionally-stabilizing or cushioning layers. The fabric is furthersurface-stabilized. Laminates having a flat fabric face, however, tendto delaminate or fray at the edges unless the fabric is thoroughlyimpregnated with adhesives. Unfortunately, impregnation with adhesivesadversely affects the textile feel and cushioning quality of thelaminate.

Because of these shortcomings, the need remains to provide a surfacecovering material that combines the desirable properties of both solidsurface coverings and textile-type coverings into a single product.Suitable surface coverings would have at least some of the desiredproperties of surface stability, edge fray resistance, thermalstability, structural stability, dimensional stability, dirt resistance,bacteria resistance, soft textile hand, cushioning, and appearanceextending over a full spectrum of tufted, knit, non-woven, woven, velourand velvet products.

SUMMARY OF THE INVENTION

Composite materials in accordance with the present invention utilize afibrous face layer combined with an adhesive layer to form a multi-layerstructure. In order to provide the desired level of surface stability,the surface fibers of the fibrous face layer form loops, and the loopsdescend into the adhesive layer and are anchored in the adhesive layer.The loops are densely spaced and shallow. Although any portion of thefibers or legs of the looped fibers in the face layer can be dispersedin the adhesive, a significant amount or substantially all of thedescending fibers are dispersed in the adhesive layer, which is incontact with the face layer. A characteristic of this invention is thatshort and densely spaced fiber loops embedded in adhesive provideimproved surface stability and retention of appearance under repeatedloading. Another characteristic is the resistance to cut-edge fraying.

In order to maintain the desired aesthetic qualities of the compositematerial while achieving increased surface stability, the amount ofpenetration of the adhesive into the face layer is controlled. Theadhesive layer is not allowed to penetrate into the top portion of theface layer. Therefore, the top of the face layer maintains its textilefeel.

Various types of fibrous face layer constructions can be used dependingupon the aesthetics desired and a balance of cost vs. performanceRegardless of the type of fibrous layer used, all of the embodiments andarrangements illustrated herein have a relatively fine and dense surfacetexture and they can also be embossed to produce three-dimensionaltextured products. In addition, a three layer composite structure can beprovided wherein a backing layer is also bonded or laminated to theadhesive layer such that the adhesive layer is disposed between the facelayer and the backing layer. Added structural rigidity is provided byhaving the adhesive layer penetrate into the backing layer as well.

To prepare a composite material in accordance with the presentinvention, a fibrous face layer is arranged to have a relatively smoothtop surface with a high density of fiber loop legs extending downthrough the thickness of the face layer to the bottom surface. Anadhesive layer is brought into direct contact with the bottom surface ofthe face layer and embedded into the face layer to cause the adhesive topenetrate partially into the thickness of the face layer. In order toembed the adhesive layer in the face layer, pressure and heat can beapplied. For a three layer laminate, the backing layer can be broughtinto direct contact with the adhesive layer before the adhesive layer isembedded into the face layer, allowing the adhesive layer tosimultaneously penetrate into the backing layer. The adhesive layer maybe pre-integrated onto the face layer or onto the backing layer beforelamination. The adhesive layer may also contain non-adhesive reinforcingor blended components. The backing layer may also contain adhesivecomponents, which may replace the need for a separate adhesive layer, ifthe adhesive is present in sufficient quantity to anchor and envelopethe legs of the surface fiber loops descending into it.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a schematic representation of a three layer embodiment of thecomposite material in accordance with the present invention;

FIG. 2 is schematic representation of another three layer embodiment ofthe composite material;

FIG. 3 is a schematic representation of another three layer embodimentof the composite material;

FIG. 4 is a schematic representation of another three layer embodimentof the composite material;

FIG. 5 is a schematic representation of a non-woven fabric layer;

FIG. 6 is schematic representation of a needle punched non-woven fabriclayer;

FIG. 7 is a schematic representation of a needle punched non-woven facelayer embodiment of the present invention before lamination;

FIG. 8 is schematic representation of a needle punched non-woven facelayer embodiment of the present invention after lamination;

FIG. 9 is a schematic representation of a non-woven fabric layer incontact with an adhesive layer;

FIG. 10 is a schematic representation of a non-woven fabric layer needlepunched through an adhesive layer;

FIG. 11 is a schematic representation of a non-woven fabric layer incombination with an adhesive layer and a backing layer;

FIG. 12 is a schematic representation of a non-woven fabric layer needlepunched through an adhesive layer and a backing layer before lamination;

FIG. 13 is a schematic representation of a non-woven fabric layer needlepunched through an adhesive layer and a backing layer after lamination;

FIG. 14 is a schematic representation of a stitchbonded fabric layerbefore gathering;

FIG. 15 is a schematic representation of a stitchbonded fabric layerafter gathering;

FIG. 16 is a schematic representation of a gathered stitchbonded fabriclayer in combination with an adhesive layer and a backing layer beforelamination;

FIG. 17 is a schematic representation of a gathered stitchbonded fabriclayer in combination with an adhesive layer and a backing layer afterlamination;

FIG. 18 is a schematic representation of a stitchbonded fabric layerhaving an adhesive layer before gathering;

FIG. 19 is a schematic representation of a stitchbonded fabric layerhaving an adhesive layer after gathering;

FIG. 20 is a schematic representation of a pattern bonded fabric layerbefore bonding and gathering;

FIG. 21 is a schematic representation of a pattern bonded fabric layerafter bonding and before gathering;

FIG. 22 is a schematic representation of a gathered pattern bondedfabric layer in combination with an adhesive layer and a backing layerbefore lamination;

FIG. 23 is a schematic representation of a gathered pattern bondedfabric layer in combination with an adhesive layer and a backing layerafter lamination;

FIG. 24 is a schematic representation of a pattern bonded fabric layerhaving an adhesive layer before bonding and gathering;

FIG. 25 is a schematic representation of a pattern bonded fabric layerhaving an adhesive layer after bonding and before gathering;

FIG. 26 is a schematic representation of a bonded and gathered patternbonded fabric layer having an adhesive layer;

FIG. 27 is a schematic representation of a reversed pile knit fabric foruse in the present invention;

FIG. 28 is a schematic representation of a reversed pile knit fabrichaving cut and raised free fiber ends for use in the present invention;

FIG. 29 is a schematic representation of a woven fabric for use in thepresent invention;

FIG. 30 is a schematic representation of a woven fabric having cut andraised free fiber ends for use in the present invention;

FIG. 31 is a schematic representation of an embodiment of an apparatusfor stabilizing a woven or knit face layer during cutting and raising offibers; and

FIG. 32 is a schematic representation of another embodiment of anapparatus for stabilizing a woven or knit face layer during cutting andraising of fibers.

DETAILED DESCRIPTION

Referring initially to FIGS. 1-4, a fabric-faced composite material 10in accordance with the present invention includes a face layer 12containing a plurality of fibers. Suitable fabrics for face layer 12include, but are not limited to, woven, non-woven, knit, stitchbonded orgathered structures. The face layer 12 includes top side or surface 16and bottom side or surface 18 opposite top surface 16, definingthickness 20 of face layer 12 between them. Top surface 16 is thesurface or face of composite material 10 that is exposed when thelaminate 10 is installed, for example on a substrate in a flooringapplication.

Composite material 10 also includes adhesive layer 22 disposed adjacentface layer 12 in direct contact with bottom surface 18. Preferably,adhesive layer 22 is continuous or is composed of a single, smoothuninterrupted surface. Alternatively, adhesive layer 22 has asubstantially constant thickness. Adhesive layer 22 can containthermoplastic or thermosetting adhesives. Suitable materials foradhesive layer 22 include polyethylene, polypropylene, copolyester,copolyamide and combinations thereof. Suitable basis weights foradhesive layer 22 range from about 3 oz/yd² to about 14 oz/yd²,preferably about 4 oz/yd² to about 10 oz/yd².

Adhesive layer 22 penetrates into face layer 12 distance 24, which issufficient to anchor face layer 12 and adhesive layer 22 together. Inone embodiment, distance 24 ranges from about ¼ to about ¾ of thickness20 of face layer 12. Preferably, adhesive layer 22 does not penetratecompletely through to top surface 16 of face layer 12 in order topreserve the soft, textile feel of composite material 10. The depth ofpenetration of adhesive layer 22 into face layer 12 can be controlled byvarying the construction of face layer 12, the construction of adhesivelayer 22 or the process conditions used to embed adhesive layer 22 intoface layer 12. In one embodiment, the viscosity of adhesive layer 22 isadjusted to limit the depth of penetration to within the lower ¾ of facelayer 12 so that at least the upper ¼ of face layer 12 is free ofadhesive. The average height 60 of the face layer above the averagelevel of adhesive penetration varies between about 0.5 mm and about 2.0mm, and the basis weight is in the range of about 100 grams/m² to about500 grams/m².

In general, the penetration of adhesive layer 22 into face layer 12increases the amount or surface area of the adhesive layer that is incontact with the structure or fibers of the face layer 12. Increasingthe surface area contact between adhesive layer 22 and face layer 12increases the strength of the bond between the two layers and theoverall rigidity and strength of the resulting two layer laminate.Overall, this arrangement yields a composite material 10 with improvedstructural strength and rigidity and a pleasurable soft texture.

Although composite materials 10 in accordance with the present inventioncan contain just two layers, face layer 12 and adhesive layer 22,additional layers may also be included. In three layer arrangements asillustrated in FIGS. 1-4, composite material 10 also includes backinglayer 26 in direct contact with adhesive layer 22. Backing layer 26 isdisposed such that adhesive layer 22 is disposed between backing layer26 and face layer 12. In order to provide increased structural rigidity,adhesive layer 22 also preferably penetrates or extends into backinglayer 26. Additional layers such as a gas permeable layer, bactericidelayer or the like can also be added. As used herein, backing layerincludes any layer, composite or laminate being attached to composite10. Composite 10 can also be embossed and simultaneously bonded and/orlaminated to any backing layer.

In either the two layer or three layer embodiments of the currentinvention, the layers are laminated together by applying pressure andheat, preferably from top surface 16, to cure or melt adhesive layer 22and to control the depth of adhesive penetration. For thermosettingadhesives, adhesive layer 22 can be applied to bottom surface 18 of facelayer 12 or to the top of backing layer 26 and the resultant structurecan be cured under pressure with a hot tool at a temperature that curesadhesive layer 22 but leaves the fibers in face layer 12 and backinglayer 26 intact. For thermoplastic adhesives, adhesive layer 22 ispreferably pre-attached to bottom surface 18 of face layer 12 or the topface of backing layer 26 and preheated or pre-melted in-situ, forexample by applying radiant heat, before all of the layers are laminatedtogether under pressure. In one embodiment, adhesive layer 22 ispreheated before applying pressure to adhesive layer 22, face layer 12or backing layer 26.

A wide variety of materials can be used as backing layer 26 dependingupon the desired thickness, strength and flexibility of three layercomposite material 10. In one embodiment, backing layer 26 is apre-needled layer of higher-denier fibers of up to about 20 denier perfilament or fiber and weighing at least about 10 oz/yd². In anotherembodiment, backing layer 26 is a needled felt of reclaimed carpetfibers. In yet another embodiment, backing layer 26 is a used tuftedcarpet.

Although the fibers in face layer 12 at bottom surface 18 are spacedfrom backing layer 26, these fibers can alternatively extend completelythrough adhesive layer 22 and be in contact with backing layer 26. Inaddition, these fibers can extend completely through the adhesive layer22 and into the backing layer 26 and even through the entire thicknessof backing layer 26. These arrangements can be achieved by controllingthe composition of adhesive layer 22 and the process used to laminatethe three layers together as discussed below. In addition, separateprocesses, for example needle punching, can be used to interlock thefibers of face layer 12 into adhesive layer 22 and backing layer 26.

In general, the bottom surface 18 of fibrous face layer 12 includes aplurality of legs 19 dependent there from. Legs 19 are anchored intoadhesive layer 22 in composite 10 and in some embodiments extend intobacking layer 26. Legs 19 include structures of face layer 12 such asfree fiber ends of needle punched or spunlaced/hydraulically needledloops, FIG. 1, undulating gathered loops of stitchbonded or patternbonded fabrics, FIG. 2, pile loops of knit fabrics, FIG. 3, and cut andraised free fiber ends of knit and woven fabrics, FIG. 4. The term“legs” or “legs formed from loops” as used herein includes all of thesestructures or portions thereof, and also includes any remaining fiberportions of the loops that have been cut to form piles. Processes suchas laminating using pressure and heat and needle punching are used toanchor legs 19 into adhesive layer 22.

In one embodiment in accordance with the present invention as shown inFIGS. 5-8, composite material 10 includes needled, non-woven face layer12 containing a plurality of fibers 14. In one embodiment, non-wovenface layer 12 contains a web of staple fibers. Suitable staple fibersrange from about 0.5 denier to about 5 denier per filament or fiber andhave a length ranging from about 0.5 inches to about 3 inches, forming anon-woven web having a weight ranging from about 3 oz/yd² to about 14oz/yd².

Although fibers 14 are initially arranged in a generally planar patternin face layer 12 as illustrated in FIG. 5, a portion of fibers 14 areneedle punched or hydraulically needled (spunlaced) toward bottomsurface 18 as illustrated in FIG. 6. When mechanical needle punching isused, the needling density is at least over 500 penetrations per squareinch (ppsi) and preferably over 1,000 ppsi. The web of fibers 14 isneedled from top surface 16 with a relatively large number of needlepenetrations per unit area. Generally, the needle punch density is fromabout 250 needles/in² to about 2000 needles/in². In one embodiment, web14 has a needle punch density of at least about 250 needles/in².Alternatively, the needle punch density is at least about 500needles/in². Preferably, the needle punch density is at least 1000needles/in².

The product of FIG. 5 can also be formed using hydraulic needling(spunlacing). Preferably, the needled web consists of shorter fibers, upto about 2 inches long, preferably less than about 1 inch and morepreferably shorter fibers, including pulps. Also, preferably theneedling jets are relatively not dense, e.g., less than 50penetrations/inch. The needling is performed substantially or totallyfrom the top, and the needling energy is relatively high, e.g., at least20 HP·HR/lb.

In this embodiment, face layer 12 is densified and acquires a relativelysmooth top surface or upper face 16 containing a plurality of loops 32facing downward. Each loop 32 contains free fiber ends or legs 34 thatdescend through face layer 12 and terminate at bottom surface 18. Inorder to form a three layer configuration of this embodiment, adhesivelayer 22 is placed in direct contact with bottom side 18 and backinglayer 26 such that adhesive layer 22 is disposed between face layer 12and backing layer 26 as is shown in FIG. 7. After activation of adhesivelayer 22 as shown in FIG. 8, adhesive layer 22 penetrates partially intoface layer 12 and backing layer 26, laminating all three layerstogether. Needled fibers 14 are anchored in adhesive layer 22 at legs 34of loops 32. The upper strata or layers of face layer 12 remain free ofadhesive from adhesive layer 22.

Preferably, in this embodiment, the selected non-woven face layer 12,FIG. 5, is needle punched or spunlaced (hydraulically needled) toproduce a plurality of free fiber ends 34 at bottom surface 18, FIG. 6.Continuous adhesive layer 22 is then placed in direct contact withbottom surface 18, FIG. 7, and adhesive layer 22 is embedded into facelayer 12 a sufficient distance to anchor face layer 12 in adhesive layer22. In order to embed adhesive layer 22 into face layer 12, adhesivelayer 22 is heat activated. Pressure may also be applied to top surface16 of face layer 12. A variety of methods can be used to apply heat andpressure to top surface 16 such as contacting top surface 16 with one ormore heated pressure plates (not shown). Adhesive layer 22 may also bepreheated as for example with radiant heat before placing face layer 12upon it.

Referring to FIGS. 9 and 10, face layer 12 is brought into directcontact with adhesive layer 22 before face layer is needle punched, FIG.9. Then, face layer 12 is needle punched so that free fiber ends 34penetrate into and in some cases completely through adhesive layer 22.Spunlacing or hydraulic needling is not applicable with the embodimentshown in FIGS. 9 and 10. In this embodiment, adhesive layer 22 mayconstitute a low-melt thermoplastic sheet or layer, e.g. polyethylene,polypropylene, low-melt copolyester or copolyamide. This sheet or layercan be in the form of a film or fabric, for example a non-woven fabric,or a layer of low-melt fibers. After the fibers are needle punched intoadhesive layer 22, adhesive layer 22 is heat activated and laminated toface layer 12 using pressure as described above.

Referring to FIGS. 11-13, in addition to bringing adhesive layer 22 intocontact with face layer 12 prior to needle punching, backing layer 26can also be brought into contact with adhesive layer 22 before needlepunching. In this three layer embodiment, backing layer 26 is placed indirect contact with adhesive layer 22 such that adhesive layer 22 isdisposed between backing layer 26 and face layer 12 (FIG. 11). Then,face layer 12 is needle punched resulting in fiber ends 34 that extendcompletely through adhesive layer 22 and into backing layer 26 (FIG.12). The composite material 10 is then finished by heat activatingadhesive layer 22 in-situ with or without substantial applied pressure(FIG. 13). In this embodiment, backing layer 26 is preferably a heavierand more resilient structure than face layer 12 so that backing layer 26does not collapse as a result of the dense needling action.

Referring to FIGS. 14-17, another embodiment of the composite material10 in accordance with the present invention is illustrated wherein facelayer 12 is an undulated, gathered or folded structure with theplurality of fibers disposed in a gathered layer forming a plurality ofdownwardly facing loops 40 disposed at top surface 16 and descendingfrom top surface 16 to bottom surface 18 and a plurality of upwardlyfacing loops 42 disposed at bottom surface 18 and ascending through facelayer 12.

Suitable gathered structures include creped webs, microfolded webs,non-wovens, wovens, and knits. The structures also include webs,non-wovens, knits and wovens that are stitched with shrinkable yarns andpost-shrunk to form folded structures. Suitable shrinkable yarns includestretched elastic yarns, partially oriented yarns, and flat, fullyoriented yarns heated near the melting points of the yarns to cause theyarns to shrink. Polyolefin yarns are also suitable for shrinking 5-20°C. below their melting points. Face layer 12 can also include aplurality of secondary non-shrinking yarns (not shown) in contact withthe stitching substrate. These secondary yarns can be stitched-in orlaid-in yarns.

As illustrated in FIG. 15, face layer 12 is a stitchbonded layer thatincludes a buckled stitching substrate 44 containing the plurality offibers and a substantially planar network of shrinkable yarns 46stitched to the stitching substrate. To produce a relatively smoothsurface, the stitching frequency is relatively high in both directions(gauge and CPI), between about 6 stitches per inch and about 30 stitchesper inch, preferably between about 10 stitches per inch and about 30stitches per inch. In addition, face layer 12, before being folded orgathered, has a fabric basis weight ranging from about 25 gm/m² to about150 gm/m². After folding and gathering, face layer has a fabric basisweight ranging from about 100 gm/m² to about 600 gm/m² and a foldedfrequency ranging from about 12 folds per inch to about 60 folds perinch. In addition, the thickness of face layer 12 is from about 0.5 mmto about 2 mm thick after folding.

In an alternative embodiment as is illustrated in FIGS. 18-19, adhesivelayer 22 can be integrated within the stitch-bonded structure of facelayer 12. In this embodiment, adhesive layer 22 can be a shrinkablelayer that assists in creating the gathered structure of face layer 12.Suitable adhesive layers include polyolefin films that shrink at about130° C. to about 160° C. by a factor of about 1.3 to about 2.2 withoutmelting. Suitable gathering frequencies and fabric weights for thisarrangement are the same as for the embodiment illustrated in FIGS. 14and 15. Suitable stitch-bonded structures of face layer 12 are disclosedin common owned, co pending patent application entitled “Stitch-bondedand Gathered Composites and Methods for Making Same,” by the sameinventor as the present invention and filed on the same day as thispatent application.

In order to make the composite material 10 of the embodiment illustratedin FIGS. 14-17, stitching substrate 44 containing the plurality offibers is selected and stitchbonded using shrinkable yarn 46 inaccordance with the desired fabric weight and gathered density, FIG. 14.Shrinkable yarn 46 is then shrunk to produce the gathered fabricstructure, FIG. 15. Adhesive layer 22 is then brought into contact withbottom surface 18 of gathered face layer 12 and embedded into face layer12 to form a two-layer laminate. Adhesive layer 22 is embedded into facelayer 12 by applying heat and pressure. Although adhesive layer 22 ispreferably in direct contact with the technical bottom surface 18 offace layer 12, adhesive layer 22 may alternatively be placed in directcontact with the technical top surface 16 of face layer 12. If a threelayer laminate is being made, backing layer 26 is brought into contactwith adhesive layer 22 prior to application of the heat and pressure sothat adhesive layer 22 also penetrates into backing layer 26, FIGS. 16and 17.

In another embodiment as illustrated in FIGS. 20-23, face layer 12 is athin and dense gathered, pattern bonded layer containing face layersubstrate 50 containing a plurality of fibers and shrinkable sublayer 52attached or bonded to face layer substrate 50 with a spaced pattern of aplurality of discrete bonds 54, FIG. 21, placed at frequencies similarto the stitch frequencies of the embodiments illustrated in FIGS. 14-17.Heated pattern bonding tool 55 is used to produce bonds 54. Face layer12 is a fibrous web or fabric having a total buckled thickness of fromabout 0.5 mm to about 2 mm. Shrinkable sublayer 52 is preferablyrelatively open to allow the penetration of the thermoplastic orthermoset adhesive from adhesive layer 22 into face layer 12. As withother embodiments of the present invention, thermoset or thermoplasticadhesives may benefit from the pre-application of adhesive layer 22 toone or both mating surfaces. Thermoplastic lamination may also benefitfrom preheating to accelerate the lamination process.

As shown in FIGS. 24-26, adhesive layer 22 can be integrated into thestructure of face layer 12 before substrate 50 is bonded to shrinkablesublayer 52. In order to be integrated into face layer 12, adhesivelayer 22 is placed in direct contact with shrinkable sublayer 52 suchthat shrinkable layer 52 is disposed between adhesive layer 22 andsubstrate 50, FIG. 24. In this embodiment, adhesive layer 22 ispreferably a shrinkable layer. The three layers are then bonded togetherwith the discrete bonds 54, FIG. 25. Following bonding, shrinkablesublayer 52 and, if applicable, adhesive layer 22 are shrunk to producegathered face layer 12, FIG. 26.

In order to make the composite material in accordance with thearrangements illustrated in FIGS. 20-23, fibrous substrate 50 isselected and shrinkable substrate 52 placed in contact with fibroussubstrate 50, FIG. 20. Fibrous substrate 50 and shrinkable substrate 52are then bonded together in a pattern similar in frequency to thosedepicted in FIGS. 14-19 in accordance with the desired fabric weight andgathered density. Suitable methods for pattern bonding these layerstogether include applying heated pattern plate 55 containing the desiredpattern to top surface 56 of substrate 50, FIG. 21. Shrinkable substrate52 is then shrunk to produce the gathered face layer structure, FIG. 22.Adhesive layer 22 is then brought into contact with bottom surface 18and embedded into face layer 12 for example by applying heat andpressure. If a three layer laminated is being made, backing 26 isbrought into contact with adhesive layer 22 prior to application of theheat and pressure so that adhesive layer 22 also penetrates into backinglayer 26, FIG. 23.

In another embodiment in accordance with the present invention asillustrated in FIG. 3, face layer 12 is a reversed knit or woven pilefabric layer. Suitable reversed knit or woven pile fabrics include thoseused to prepare velours or velvets. Pile side 58 of face layer 12 issufficiently long to provide for adequate embedding of adhesive layer 22into face layer 12 to stabilize face layer 12. Suitable fabrics havebasis weights that range from about 4 oz/yd² to about 16 oz/yd²,preferably about 6 oz/yd² to about 12 oz/yd² (about 200 gm/m² to about400 gm/m²). As in the case of surface layers 12 in accordance with thepresent invention, fabric face layer 12 provides a durable anddecorative surface that utilizes finer and softer fibers that can beapplied over backing layer 26 containing lower-cost, stiffer fibers toprovide cushion, body, and dimensional stability.

In order to make composite material 10 in accordance the embodiment ofFIG. 3, knit or woven pile fabric face layer 12 is selected and adhesivelayer 22 is brought into direct contact with bottom surface 18 of facelayer 12. Adhesive layer 22 is then embedded into fabric face layer 12,for example by the application of heat and pressure. If a three layerarrangement is desired, backing layer 26 is brought into direct contactwith adhesive layer 22 before adhesive layer 22 is embedded into fabricface layer 12 so that adhesive layer 22 will also embed or penetrateinto backing layer 26.

Referring to FIGS. 27 and 28, when face layer 12 is a knit fabric, facelayer 12 contains a plurality of overlaps 60 on top surface 16 and aplurality of underlaps 61 on bottom surface 18. In order to provide forstronger bonding between knit fabric face layer 12 and adhesive layer22, underlaps 61 can be cut, sanded, brushed or sheared at bottomsurface 18 to produce a plurality of cut and raised fibers 62. Whenlaminated to adhesive layer 22, adhesive layer 22 will embed into fabricface layer 12 throughout the area of cut and raised fibers 62. Thisembodiment utilizes many different kinds of knits. Suitable knitscontain underlap loops 61 that can be cut and raised on back surface 18without affecting the texture of top surface 16.

Referring to FIGS. 29 and 30, face layer 12 contains a woven fabrichaving a plurality of warp yarns 64 and a plurality of weft yarns 66.Weft yarns 66 have been cut, sanded, brushed or sheared on one surfaceof woven fabric face layer 12 in a manner that leaves yarn overlaps 68of interconnecting warp yarns 64 intact and produces a plurality of cutand raised fibers 62 at bottom surface 18.

In order to make a composite material in accordance with the embodimentsillustrated in FIGS. 27-30, a knit or woven face layer 12 is selectedand the pile loop side for the knit fabric or one side of the wovenfabric is sanded or cut to produce cut and raised fibers 62. Adhesivelayer 22 is then brought into direct contact with cut and raised fibers62 and embedded into face layer 12. Adhesive layer 22 can be embedded bythe application of pressure and heat. If a three layer embodiment isdesired, backing layer 26 is brought into contact with adhesive layer 22before adhesive layer 22 is embedded into face layer 12 so that adhesivelayer 22 will also penetrate into backing layer 26.

Since knit or woven face layer 12 is being cut or abraded, which weakensthe structural integrity of the fabric, face layer 12 can be stabilizedbefore being cut or sanded to assist in preserving the knit or wovenstructure during cutting or shearing. Stabilization or immobilizationcan be achieved by attaching a stabilizing sheet or a temporary layer ofadhesive to top surface 16 prior to cutting, sanding or abrading bottomsurface 18. Following cutting, lamination of face layer 12 to the otherlayers can be performed with the face stabilizer left in place orremoved.

In another embodiment of stabilizing face layer 12 as illustrated inFIGS. 31 and 32, face layer 12 can be stabilized on high friction roller70. As illustrated, a continuous feed of face layer 12 from face layerroll 72 is introduced onto high friction roller 70. Face layer 12 isthen exposed to sanding roller 74, brushing roller 76 or napping roller78 producing cut and raised fibers 62 while stabilizing top surface 16.Backing layer 26 and adhesive layer 22 are brought into contact witheach other and heated and then laminated to face layer 12 while facelayer 12 is still immobilized on high friction roller 70. Optionally,roller 70 may be heated. The finished composite material is thencollected on take-up roller 80. Adhesive layer 22 can be introduced as acontinuous sheet, FIG. 31, applied to backing layer 26 using a sprayheads 82, FIG. 32, or applied to backing layer 26 as a foam 84 that isthen doctor knifed 86 to the desired thickness, FIG. 32.

EXAMPLES Example 1

A blend of 80% 1.5 denier 1.5 inch polyester fibers and 20% 1.5 denier1.5 inch polypropylene fibers is carded and lapped into a structureweighing approximately 8 oz/sq.yd. This face layer is then needled fromone side only with 1,500 penetrations/sq.in. forming a dense surface anda very fur-like backface with many free ends and loops, as shown in FIG.6.

A second blend of 80% 15 denier, 1.5 inch cut polyester and 20% 1.5denier 1.5 cut polypropylene fiber is carded and lapped into a 24oz/sq.yd batt and needled with 300 penetrations per square inch from oneface to form the backing layer.

A dual layer of 0.05 inch thick polyethylene utility films is placedbetween the face layer and the backing layer, with the needled sides ofthe face layer and the backing on the outside and pressed with a plateheated to about 200 degrees C. placed against the face layer, at 1000psi for 3 seconds. The plate facing the backing is at room temperature.The product is solidly laminated with all free fiber ends embedded inthe molten polyethylene. Adhesive penetrates the two layers, but leavesa thickness of face layer approximately 1 mm thick free of adhesive.Delamination cannot be achieved without damage to the face or backinglayers. The surface is smooth, durable and traffic-wear resistant with atextile feel and improved edge-fraying resistance.

Example 2

The face layer of Example 1 is needled into the adhesive layer beforelaminating onto the backing layer. The stability of the surface issuperior to Example 1. Delamination without destroying the layers iseven more difficult. The surface is fibrous, smooth, free of adhesiveand traffic-wear and edge-fraying resistant. The fibrous height abovethe adhesive penetration is approximately 0.9 mm.

Example 3

The needled face layer of Examples 1 and 2 is needled directly throughthe dual adhesive layer and into the backing (FIG. 12) before the hotpressing process. The product has a textile feel and excellentdurability and is delamination resistant.

Example 4

A non-woven fabric containing commercial polyester Sontara® spunlacedStyle 8034 (20 g/m²), sold by E. I. DuPont de Nemours, is stitched withP.O.Y. polyester yarn (155 denier/34 filament) using a stitch pattern of1,0/3,4 at 14 gauge and 12 cpi. After stitching the product is subjectedto 190 degrees C. for 30 seconds within a tentering frame, allowing itto shrink by a ratio of 1.7/1 both in the machine and cross directions.It forms a thin and dense undulated folded fabric structure as shown inFIG. 15. This fabric is placed over the dual layers of adhesive andbacking of Example 1 and laminated as described in Example 1. Thecomposite is very stable and traffic-wear resistant and has a textilefeel with improved resistance to edge-fraying. Loop density isapproximately 22/inch in both directions and loop height above theadhesive penetration is approximately about 1 mm.

Example 5

The stitching bonding step for the face layer of Example 4 is repeatedwith an additional layer of 5.5 mil thick polyethylene adhesive filmplaced over the Sontara® nonwoven. After shrinking by a ratio of 1.6/1in both directions by subjecting it to 150 degrees C. for 30 secondswithin a frame, a buckled face layer containing an added layer ofpolyethylene on its technical back is produced (FIG. 19). The compositeis laminated to the backing of Example 1 under the same conditions withthe same excellent results.

Example 6

In this example, a folded layer produced by shrinking a dualshrinkable/non-shrinkable laminate is illustrated. A buckled face layeris constructed by intermittently “tacking” a layer of Style 8003spunlaced non-woven polyester Sontara® (1.9 oz/yd² or about 50 gm/m²) toa shrinkable sublayer consisting of a carded web of polypropylene stapleweighing 30 gm/m². The bonding pattern consists of elevated lines 0.5 mmthick extending across every 2 mm. Tacking is preformed using a heatedpatterned plate that is heated to 200 degrees C. and placed on thepolyester side using 1000 psi for about 2 seconds. The polypropyleneside rests against a room temperature steel plate.

Upon heating the composite to 150 degrees C., the polypropylene layershrinks to approximately 67% of its initial length, producing anundulated structure (FIG. 22). This undulated face layer is placed overa dual layer of 5.5 mil thick polyethylene over the same backing used inExamples 1 and pressed in the same manner to produce a very coherentlaminate with a textile feel, and improved edge-fraying resistance.

Example 7

In this example, a folded layer containing a shrinkable adhesive layer,produced by pattern bonding and shrinking is illustrated. The process ofExample 6 is repeated with a layer of polyethylene adhesive placed underthe spunlaced sheet before tacking to the shrinkable backing (FIG. 24).The assembly is pretacked and shrunk at 150 degrees C. to produce thecomposite face and adhesive layer.

Subjecting this composite face/adhesive layer to the same laminationprocess in Example 6 over the same backing resulted in excellentadhesion, surface stability and edge fraying resistance.

Example 8

In this example, a face layer consisting of commercial velour knit isapplied with the pile face down against the adhesive layer. A commercialknit nylon velour fabric that was 1.1 mm thick and weighed 12.8 oz/yd²was laminated to the backing described above using the 5.5 milpolyethylene film described above, by pressing from one face only with aplaten at 200 degrees C. for 1 second with the pile facing the adhesivefilm. Fabric thickness above the adhesive penetration line wasapproximately 0.9 mm. Excellent adhesion, surface stability and textilehand resulted. The product was highly resistant to edge fraying.

Example 8A (Prior Art)

The velour knit was laminated with the pile face up. Adhesion and edgefraying resistance were not achieved until pressure and time wereincreased over 3 seconds with some adhesive rising near the top of theface layer. This example is outside the scope of the present invention.

Example 9 (Prior Art)

This example illustrates how a commercial cotton denim fabric that doesnot respond well to thermoplastic lamination can be converted to producehigh-performance composite in accordance with the present invention.

A commercial woven cotton fabric weighing 12.8 oz/yd² was laminated tothe backing described above using the dual polyethylene films describedabove in a heated press. Top surface temperature was varied between 180and 230 degrees C. Pressure at each step was varied between 150 and10,000 psi, and the pressing time at each temperature combination wasbetween about 0.5 and about 3 seconds. Lamination without relative easeof delamination was not achieved without penetrating the woven withpolyethylene adhesive in spots or over the entire surface area. Surfacestability versus traffic wear resistance also could not be achievedunless the adhesive resin rose to the top of the face layer. The cutedges of this composite frayed easily. This example is also outside thescope of the present invention.

Example 10

The cotton woven mentioned in Example 9 was prestabilized byprelaminating onto commercial pressure sensitive Duct Tape. Thestabilized product was held on a table top and hand sanded on theopposing face using a pad of 150 grit sandpaper until a uniform shadechange indicated that practically all of the originally exposed yarnsunderneath were cut, and the face fabric assumed a highly openvelvet-like surface. The fabric was then laminated onto the backing usedin the above examples using a single layer of polyethylene, and pressingat 10,000 psi with the top plate heated to 180 degrees C. for 3 seconds.The pressure sensitive tape was removed, with minimal tape adhesivecontamination remaining in a few spots on the surface. Excellentlamination, without a tendency to fray at cut edges and with anadhesive-free textile surface was achieved. The product had excellentsurface stability versus traffic-wear resistance. The cut edges werehighly resistant to fraying.

Although specific forms of the invention have been selected forillustration in the drawings and the preceding description is drawn inspecific terms for the purpose of describing these forms of theinvention fully and amply for one of average skill in the pertinent art,it should be understood that various substitutions and modificationswhich bring about substantially equivalent or superior results and/orperformance are deemed to be within the scope and spirit of thefollowing claims.

1-55. (canceled)
 56. A composite comprising a fibrous face layer havinga top surface and a bottom surface, an adhesive layer having a topsurface and a bottom surface and a backing layer, wherein the bottomsurface of the fibrous face layer faces the top of the adhesive layerand the bottom surface of the adhesive layer faces the backing layer,wherein the fibrous face layer comprises a gathered fabric forming aplurality of legs extending away from the top surface of the fibrouslayer, said legs comprise undulated folds or gathers from the fibrousface layer, wherein the legs of the fibrous face layer are bonded to theadhesive layer and wherein the top surface of the fibrous face layer issubstantially free of adhesive, wherein the adhesive layer is at leastpartially bonded to the backing layer.
 57. A composite comprising afibrous face layer having a top surface and a bottom surface, anadhesive layer having a top surface and a bottom surface and a backinglayer, wherein the bottom surface of the fibrous face layer faces thetop of the adhesive layer and the bottom surface of the adhesive layerfaces the backing layer, wherein the fibrous face layer comprises a knitor woven fabric forming a plurality of legs extending away from the topsurface of the fibrous layer, said legs comprise pile loops of the knitor woven fabric, wherein the legs of the fibrous face layer are bondedto the adhesive layer and wherein the top surface of the fibrous facelayer is substantially free of adhesive, wherein the adhesive layer isat least partially bonded to the backing layer.
 58. A compositecomprising a fibrous face layer having a top surface and a bottomsurface, an adhesive layer having a top surface and a bottom surface anda backing layer, wherein the bottom surface of the fibrous face layerfaces the top of the adhesive layer and the bottom surface of theadhesive layer faces the backing layer, wherein the fibrous face layercomprises a cut, sanded, sheared or brushed woven or knit forming aplurality of legs extending away from the top surface of the fibrouslayer, said legs are made from the cut, sanded, sheared or brushedportion of the fibrous face layer, wherein the legs of the fibrous facelayer are bonded to the adhesive layer and wherein the top surface ofthe fibrous face layer is substantially free of adhesive, wherein theadhesive layer is at least partially bonded to the backing layer. 59.The composite of claim 56, wherein the adhesive layer penetrates intothe fibrous face layer by an application of pressure.
 60. The compositeof claim 57, wherein the adhesive layer extends at least partially intothe face layer by an application of pressure.
 61. The composite of claim58, wherein the adhesive layer extends at least partially into the facelayer by an application of pressure.
 62. The composite of claim 56,wherein a top portion of the fibrous face layer above the top of theadhesive layer has a thickness of about 0.5 mm to about 2.0 mm.
 63. Thecomposite of claim 56, wherein a top portion of the fibrous face layerabove the top of the adhesive layer has a basis weight of about 100grams/m² to about 500 grams/m².
 64. The composite of claim 56 beingembossable to form a three-dimensional textured product.
 65. Thecomposite of claim 56, wherein the fibrous face layer comprises fibersof about 0.5 denier to about 5.0 deniers.
 66. The composite of claim 56,wherein the adhesive layer penetrates into about ¼ to about ¾ of thefibrous face layer.
 67. The composite of claim 57, wherein a top portionof the fibrous face layer above the top of the adhesive layer has athickness of about 0.5 mm to about 2.0 mm.
 68. The composite of claim57, wherein a top portion of the fibrous face layer above the top of theadhesive layer has a basis weight of about 100 grams/m² to about 500grams/m².
 69. The composite of claim 57 being embossable to form athree-dimensional textured product.
 70. The composite of claim 57,wherein the fibrous face layer comprises fibers of about 0.5 denier toabout 5.0 deniers.
 71. The composite of claim 57, wherein the adhesivelayer penetrates into about ¼ to about ¾ of the fibrous face layer. 72.The composite of claim 58, wherein a top portion of the fibrous facelayer above the top of the adhesive layer has a thickness of about 0.5mm to about 2.0 mm.
 73. The composite of claim 58, wherein a top portionof the fibrous face layer above the top of the adhesive layer has abasis weight of about 100 grams/m² to about 500 grams/m².
 74. Thecomposite of claim 58 being embossable to form a three-dimensionaltextured product.
 75. The composite of claim 58, wherein the fibrousface layer comprises fibers of about 0.5 denier to about 5.0 deniers.